Power tool and battery pack for use with the same

ABSTRACT

A battery pack for use with a power tool and including a housing having an internal cavity in which one or more battery cells are supported. The housing has a set of openings. A printed circuit board is supported within the housing and in electrical communication with the battery cells. Battery pack contacts are coupled to and in electrical communication with the printed circuit board. A terminal block is supported by the printed circuit board and encloses the battery pack contacts. Each of the battery pack contacts are accessible through one of the set of openings in the housing and the terminal block. A first gasket is positioned between a first wall of the terminal block and the housing and a second gasket is positioned between a second wall of the terminal block and the printed circuit board.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to co-pending U.S. Provisional PatentApplication No. 62/812,738 filed on Mar. 1, 2019, the entire contents ofwhich are incorporated herein by reference.

BACKGROUND

The present invention relates to electric devices (e.g., power tools)and a battery for use with electric devices.

It is important to the health of a power tool and a battery pack for usewith a power tool to prevent water and other debris from infiltratingthe same. Water and other debris can result in deterioration of theinternal components of the power tool and the battery pack.

SUMMARY

In one embodiment a power tool system is disclosed. The power toolsystem includes a power tool that has a housing with a battery-receivingportion that removably receives a battery pack, and device contactssupported by the housing. The device contacts are configured tomechanically and electrically interface with the battery pack. Thebattery pack includes a housing that has an internal cavity in which oneor more battery cells are supported and a set of openings. A framemember is positioned within the housing. A printed circuit board issupported within the housing by the frame member, and the battery cellsare in electrical communication with the printed circuit board. Batterypack contacts are coupled to and in electrical communication with theprinted circuit board, and each of the battery pack contacts areaccessible through one of the set of openings in the housing. A terminalblock is supported by the printed circuit board and encloses the batterypack contacts. The battery pack contacts are accessible through a firstwall of the terminal block. A first gasket is positioned between a firstwall of the terminal block and the housing, and the first gasket has asurface that abuts the first wall and at least a portion of the framemember. A second gasket is positioned between a second wall of theterminal block and the printed circuit board.

In another embodiment a battery pack for use with a power tool isdisclosed. The battery pack includes a housing having an internal cavityin which one or more battery cells are supported and a set of openings.A printed circuit board is supported within the housing, and the batterycells are in electrical communication with the printed circuit board.Battery pack contacts are coupled to and in electrical communicationwith the printed circuit board, and each of the battery pack contactsare accessible through one of the set of openings in the housing. Aterminal block is supported by the printed circuit board and enclosesthe battery pack contacts. The terminal block includes a wall having afirst set of openings, and each of the openings in wall correspond toone of openings in the housing. A gasket is positioned between the firstwall of the terminal block and the housing. The gasket includes a set ofopenings, and each of the openings corresponds to one of the openings inthe housing of the battery pack and one of the set of openings in theterminal block.

In another embodiment a battery pack for use with a power tool isdisclosed. The battery pack includes a housing having an internal cavityin which one or more battery cells are supported and a set of openings.A printed circuit board is supported within the housing, and the batterycells are in electrical communication with the printed circuit board.Battery pack contacts are coupled to and in electrical communicationwith the printed circuit board. A terminal block is supported by theprinted circuit board and encloses the battery pack contacts. Each ofthe battery pack contacts are accessible through one of the set ofopenings in the housing and the terminal block. A first gasket ispositioned between a first wall of the terminal block and the housing.The first gasket includes a first surface, a second surface that isopposite the first surface, and a third surface. The first surface is incontact with a first surface of the housing, the second surface is incontact with the wall of the terminal block, and the third surface is incontact with a second surface of the housing. A second gasket ispositioned between a second wall of the terminal block and the printedcircuit board.

Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTIONS OF THE DRAWINGS

FIG. 1 is a side view of a battery pack coupled to an electric devicehaving a battery-receiving portion.

FIG. 2 is a perspective view of the battery-receiving portion shown inFIG. 1 including electric device terminals.

FIG. 3 is a perspective view the electric device terminals of FIG. 2.

FIG. 4 is another perspective view the electric device terminals of FIG.2.

FIG. 5 is a perspective view of the battery pack shown in FIG. 1including a housing.

FIG. 6 is a perspective view of the battery pack shown in FIG. 5 with aportion of the housing removed and showing a first gasket.

FIG. 7 is a front view of the first gasket of FIG. 6.

FIG. 8 is a perspective view of the first gasket of FIG. 6.

FIG. 9 is a perspective view of a portion of the housing of the batterypack and the first gasket.

FIG. 10 is a perspective view of the battery pack of FIG. 5 with thehousing removed, the battery pack including a first gasket.

FIG. 11 is a perspective view of the battery pack of FIG. 5 with thehousing, the first gasket, and a portion of the terminal block removed.

FIG. 12 is a perspective view of the terminal block and a second gasket.

FIG. 13 is another perspective view of the terminal block and the secondgasket.

FIG. 14 is a perspective view of the auxiliary frame member.

FIG. 15 is a perspective view of the auxiliary frame member with a thirdgasket.

Before any independent embodiments of the invention are explained indetail, it is to be understood that the invention is not limited in itsapplication to the details of construction and the arrangement ofcomponents set forth in the following description or illustrated in thefollowing drawings. The invention is capable of other independentembodiments and of being practiced or of being carried out in variousways. Also, it is to be understood that the phraseology and terminologyused herein is for the purpose of description and should not be regardedas limiting.

Use of “including” and “comprising” and variations thereof as usedherein is meant to encompass the items listed thereafter and equivalentsthereof as well as additional items. Use of “consisting of” andvariations thereof as used herein is meant to encompass only the itemslisted thereafter and equivalents thereof. Unless specified or limitedotherwise, the terms “mounted,” “connected,” “supported,” and “coupled”and variations thereof are used broadly and encompass both direct andindirect mountings, connections, supports, and couplings.

Also, the functionality described herein as being performed by onecomponent may be performed by multiple components in a distributedmanner. Likewise, functionality performed by multiple components may beconsolidated and performed by a single component. Similarly, a componentdescribed as performing particular functionality may also performadditional functionality not described herein. For example, a device orstructure that is “configured” in a certain way is configured in atleast that way but may also be configured in ways that are not listed.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an electric device 10 configured to receive a batterypack 54 (e.g., a rechargeable lithium-ion battery pack). In theillustrated embodiment, the electric device is a drill, but the electricdevice may be any type of power tool, an outdoor tool, or anon-motorized device (e.g., a light, an audio device, etc.).

With reference to FIGS. 1 and 2, the electric device includes a housing40 including a battery-receiving portion 50 that defines a longitudinalaxis 52 (i.e., battery insertion axis) and has a cavity 70 defined by alower surface 74, a pair of sidewalls 78, and an end wall 82. An openend 86 is opposite the end wall 82. In addition, an upper end wall 90extends above the end wall 82 proximate the cavity 70. Device contacts94 are supported on the end wall 82 and are configured to mechanicallyand electrically interface with the battery pack 54 to transferelectrical power therebetween.

As shown in FIG. 3, in one embodiment, at least a portion of the devicecontacts 94 include a coating 98 that is an insulator. In theillustrated embodiment, the insulator is a spray acrylic, but theinsulator may have any suitable formulation. Additionally, and as shownin FIG. 4, in another embodiment, a tool gasket 100 is positionedagainst the end wall 82 and adjacent to and surrounding the devicecontacts 94. The gasket 100 compresses when a battery pack 54 isinserted.

With renewed reference to FIG. 2, the battery-receiving portion 50includes stepped grooves 104 extending between the open end 86 and theend wall 82 (e.g., as illustrated, from the open end 86 to the end wall82). The stepped grooves 104 are defined by rails 108 disposed on thesidewalls 78. The rails 108 protrude from the sidewalls 78 to define anupper extent of the grooves 104 that face the lower surface 74.

In the illustrated embodiment, the battery-receiving portion 50 alsoincludes a latching mechanism 114 that protrudes from the lower surface74 near the open end 86. The latching mechanism is coupled to anactuator 118. The latching mechanism 114 has a first position and asecond position. The latching mechanism 114 is biased (i.e., by a springor cam member, etc.) into the first position. In the first position, thelatching mechanism 114 is configured to engage the battery pack 54 tomaintain engagement between the battery pack 54 and the electricaldevice 10 within the battery-receiving portion 50. However, in otherembodiments (not shown), the latching mechanism 114 may be disposed atvarious locations (e.g., on a sidewall 78, the end wall 82, the upperend wall 90, etc.) such that the latching mechanism 114 engagescorresponding structure on the battery pack 54 to maintain engagementbetween the battery pack 54 and electrical device 10 and retain thebattery pack 54 within the battery-receiving portion 50. In the secondposition, the latching mechanism 114 is positioned within the housing 40such that the battery pack 54 is insertable into and removable from thecavity 70 without engaging with the latch mechanism 114. The actuator118 is movable to move the latching mechanism 114 from the firstposition to the second position.

With further reference FIG. 2, an ejector 138 is supported on the endwall 90. The ejector 138 includes an ejection member 142 biased by abiasing member (e.g., one or more springs (not shown)) to protrudethrough the end wall 90. When the battery pack 54 is attached to thebattery-receiving portion 50 of the housing 40, the ejection member 142is pushed into the end wall 90 to compress the biasing member. From thisposition, the ejector 138 is configured to exert a force F on thebattery pack 54 to push the battery pack 54 out of the battery-receivingportion 50 (e.g., upon release of the latching mechanism 114).

FIGS. 5, 6, and 10 illustrate the battery pack 54 for use with thebattery-receiving portion 50, described above. The battery pack 54includes a housing 150 defining an internal cavity in which one or morebattery cells 152 are supported. Each battery cell 152 may have anominal voltage between about 3 V and about 5 V and may have a nominalcapacity between about 2 Ah and about 6 Ah (in some cases, between about3 Ah and about 5 Ah). The battery cells 152 may be any rechargeablebattery cell chemistry type, such as, for example, lithium (Li),lithium-ion (Li-ion), other lithium-based chemistry, nickel-cadmium(NiCd), nickel-metal hydride (NiMH), etc.

The battery cells 152 may be connected in series, parallel, orcombination series-parallel to provide the desired electricalcharacteristics (e.g., nominal voltage, current output, currentcapacity, power capacity, etc.) of the battery pack 54. The batterycells 152 are electrically coupled to battery pack contacts 154 (FIG.11) supported on or within the housing 150 and configured toelectrically and mechanically engage the device contacts 94 tofacilitate the transfer of electrical power between the device 10 andthe battery pack 54.

Further with respect to FIG. 5, the housing 150 includes a protrusion158 supporting, at a front end 160, the battery pack contacts 154 (FIG.11). In particular, the front end 160 includes a set of openings 162.Each of the openings 162 corresponds to one of the battery pack contacts154. On each lateral side, a rail 166 extends laterally outwardly and todefine a groove 170. Proximate a rear end 174, a top surface 178 definesa slot or recess 182 sized and shaped to cooperate with the latchmechanism 114.

The battery pack 54 is coupled to the battery-receiving portion 50 byaligning the rails 166 of the battery pack 54 with the grooves 58 of thebattery-receiving portion 50, and subsequently sliding the battery pack54 along a battery insertion axis 52 until the device contacts 94 engagethe battery pack contacts 154.

It should be understood that, if the size and shape of thebattery-receiving portion 50 is modified, corresponding variations inthe size and shape of the battery pack 54 may be made. For example, thegeometric configuration of the rails 108, 166 will be consistentlyvaried in order to maintain the mating engagement between the batterypack 54 and the battery-receiving portion 50. It should be understoodthat, in other constructions (not shown), the orientation of the rails108, 166 may be reversed with the rails 108 being directed outwardly andthe rails 166 being directed inwardly.

As shown in FIGS. 6 and 10, positioned within the housing 150 is abattery cell holder 200, an auxiliary frame member 204, a first printedcircuit board (PCB) 208, a second printed circuit board 210, and aterminal block 212 (FIGS. 12 and 13). As shown in FIG. 10, the batterycell holder 200 restrains the battery cells 152. The auxiliary framemember 204 is positioned on one side of the battery cell holder 200within the housing 150. The battery cells 152 are in electricalcommunication with the first PCB 208. The first PCB 208 has a firstsurface 208 a and a second surface 208 b opposite the first surface 208a (FIG. 11), and the first PCB 208 is supported by the auxiliary framemember 204. The battery pack contacts 154 are coupled to, extend from,and are in communication with the first PCB 208. The terminal block 212is supported by the first PCB 208 and encloses the battery pack contacts154.

With respect to FIGS. 12 and 13, the terminal block 212 has a first wall212 a, a second wall 212 b, a third wall 212 c, a fourth wall 212 d, afifth wall 212 e, and a sixth wall 212 f. The six walls 212 a-212 fdefine an interior compartment 220 in which the battery pack contacts154 are positioned. The first or front wall 212 a has a first set ofopenings 228 that extend therethrough. Each of the openings 228corresponds to one of the battery pack contacts 154. Accordingly, eachof the first openings 228 is sized and shaped to receive the respectivemating device contact 94. The second or bottom wall 212 b has a secondset of openings 236 that extend therethrough. The bottom wall 212 b (andtherefore the second openings 236) are positioned to face the first PCB208, such that the battery pack contacts 154 extend from the first PCB208 through the second plurality of openings 236 and into the interior220 of the terminal block 212. The third or top wall 212 c of theterminal block 212, the fourth wall 212 d (e.g., first sidewall), fifthwall 212 d (e.g., second sidewall), and the sixth or rear wall 212 f areclosed (i.e., have no openings). The four closed walls 212 c-212 f helpprevent fluid and other debris from entering into the terminal block212.

With respect to FIGS. 6-9, a first gasket 250 is positioned adjacent tothe front wall 212 a of the terminal block 212. That is, the firstgasket 250 is positioned between and in contact with the terminal block212 and the housing 150. The first gasket 250 includes openings 254,each of which corresponds to one of the openings 162 in the housing 150of the battery pack and one of the first openings 228 in the terminalblock 212. Moreover, each of the openings 254 corresponds to one of thebattery pack contacts 154. Accordingly, each of the openings 254 issized and shaped to receive the respective mating device contact 94.Each of the openings 254 in the first gasket 250 entirely surround therespective opening 228 in the terminal block 212. In the illustratedembodiment, the first gasket 250 covers and extends beyond an outerperiphery of the first wall 212 a of the terminal block 212. That is,the first gasket 250 has a greater width 258 than a width 262 (FIG. 12)of the terminal block 212 and a greater height 266 than a height 272(FIG. 12) of the terminal block 212. More specifically, the first gasket250 includes a first width 258 a, a second width 258 b that is greaterthan the first width 258 a, and a third width 258 c that is greater thanthe second width 258 c. Each of the widths 258 a-258 c is greater thanthe width 262 of the terminal block 212. In other or additionalembodiments, the first gasket 250 may have a smaller width 258 than thewidth 262 of the terminal block 212 and a smaller height 266 than theheight 272 of the terminal block 212, as long as the first gasket 250has a width and height sufficient to entirely surround the openings 228in the terminal block 212.

Additionally, and with respect to FIG. 7, the first gasket 250 includesa first or front surface 276 that abuts a surface of the housing 150, asecond or rear surface 280 that is opposite the front surface 276, and athird or top surface 284 that abuts another surface of the housing 150.The first width 258 a corresponds to the top surface 284. The rearsurface 280 of the first gasket 250 abuts both the front wall 212 a ofthe terminal block 212 and at least a portion of the auxiliary framemember 204. A thickness 288 of the first gasket is defined between thefront and rear surfaces 276, 280. The thickness 288 corresponds to andfills a gap (not shown) between the terminal block 212 and the housing150. The gap is defined by a distance between the front wall 212 a ofthe terminal block 212 and the housing 150. The first gasket 250 createsa seal between the openings 162 in the housing 150 and the openings 228in the terminal block 212. Accordingly, the first gasket 250 preventsfluid and other debris from entering the housing 150 through theopenings 162, and also prevents any fluid and debris that may be in thehousing from entering into the terminal block 212. Moreover, the firstgasket 250 acts as an anti-vibration mechanism by taking up the gapbetween the terminal block 212 and the housing 150. That is, the firstgasket is configured to reduce vibration between the housing and theterminal block.

As shown in FIGS. 6 and 11-15, a second gasket 300 (FIGS. 11-13) ispositioned adjacent the first surface 208 a of the first PCB 208 and athird gasket 304 (FIGS. 14-15) is positioned adjacent the second surface208 b of the first PCB 208. In particular, the second gasket 300 ispositioned between the terminal block 212 and the first surface 208 a ofthe first PCB 208, while the third gasket 304 is positioned between thesecond surface 208 b of the PCB 212 and the auxiliary frame member 204.

As shown in FIGS. 11-13, the second gasket 300 includes a body 308 withopenings 312. Each of the openings 312 in the second gasket 300corresponds to one of the second openings 236 in the bottom wall 212 bof the terminal block 212. The second gasket 300 acts as a seal thatprevents fluid or debris that may enter the terminal block 212 fromreaching the first PCB 208, and prevents fluid and debris that may be inthe housing from entering into the terminal block 212.

As shown in FIGS. 14-15, the third gasket 304 is sized and shaped toconform to a lip 320 of the auxiliary frame member 204. In theembodiment of FIGS. 14-15, the third gasket 304 includes first andsecond leg portions 304 a, 304 b that extend from opposite sides of acentral portion 304 c. Moreover, the lip 320 of the auxiliary framemember includes a groove 324 that is sized and shaped to receive thethird gasket 304. Accordingly, the groove 324 also includes first andsecond leg portions 324 a, 324 b that extend from opposite sides of acentral portion 324 c. The third gasket 304 keeps potting material (notshown) contained within the auxiliary frame member 204. The third gasket304 may also act as an additional seal that prevents fluid or debristhat may enter the terminal block 212 from reaching the first PCB 208,and prevents fluid and debris that may be in the housing from enteringinto the terminal block 212.

In the illustrated embodiment, each of the gaskets 250, 300, 304 areconstructed of foam. In other embodiments, each of the gaskets 250, 300,304 may be constructed from any suitable material, and the material neednot be the same for each.

In the illustrated embodiment, together, the gaskets 250, 300, 304eliminate space between various structures contained in the battery pack54. That is, the gaskets 250, 300 prevent the egress of fluid and debrisinto the housing 150. Moreover, the gaskets 250, 300 also prevent fluidand debris that are able to enter the housing 150 from reaching thefirst PCB 208 and other electrical components contained within thehousing 150 of the battery pack 54. Similarly, the first and secondgaskets 250, 300 also prevent any fluid and debris that may be in thehousing from entering into the terminal block 212. The third gasket 304helps contain the potting compound within the battery pack 54, asdiscussed above.

Although the invention has been described in detail with reference tocertain preferred embodiments, variations and modifications exist withinthe scope and spirit of one or more independent aspects of the inventionas described.

What is claimed is:
 1. A power tool system comprising: a power tool including a housing including a battery-receiving portion that removably receives a battery pack, and device contacts supported by the housing, the device contacts configured to mechanically and electrically interface with the battery pack; and the battery pack including a housing having an internal cavity in which one or more battery cells are supported, the housing having a set of openings, a frame member positioned within the housing; a printed circuit board supported within the housing by the frame member, the battery cells being in electrical communication with the printed circuit board, battery pack contacts coupled to and in electrical communication with the printed circuit board, each of the battery pack contacts being accessible through one of the set of openings in the housing, a terminal block supported by the printed circuit board and enclosing the battery pack contacts, the battery pack contacts being accessible through a first wall of the terminal block, a first gasket positioned between a first wall of the terminal block and the housing, the first gasket having a surface that abuts the first wall and at least a portion of the frame member, and a second gasket positioned between a second wall of the terminal block and the printed circuit board.
 2. The power tool system of claim 1, wherein a coating covers at least a portion of each of the device contacts, the coating being an insulator.
 3. The power tool system of claim 2, wherein the coating is a spray acrylic.
 4. The power tool system of claim 1, wherein the first gasket includes a first set of openings and the second gasket includes a second set of openings, each of the first set of openings corresponding to an on opening in the first wall of the terminal block and each of the second set of openings corresponding to an opening in the second wall of the terminal block.
 5. The power tool system of claim 1, wherein the first gasket and the second gasket prevent fluid and debris from entering the terminal block.
 6. A battery pack for use with a power tool, the battery pack comprising: a housing having an internal cavity in which one or more battery cells are supported, the housing having a set of openings; a printed circuit board supported within the housing, the battery cells being in electrical communication with the printed circuit board; battery pack contacts coupled to and in electrical communication with the printed circuit board, each of the battery pack contacts being accessible through one of the set of openings in the housing; a terminal block supported by the printed circuit board and enclosing the battery pack contacts, the terminal block including a wall having a first set of openings, each of the openings in wall corresponding to one of openings in the housing; and a gasket positioned between the first wall of the terminal block and the housing, the gasket including a set of openings, each of the openings corresponding to one of the openings in the housing of the battery pack and one of the set of openings in the terminal block.
 7. The battery pack of claim 6, wherein the gasket prevents fluid and debris from entering the openings in the housing and the openings in the terminal block
 8. The battery pack of claim 6, wherein a thickness of the gasket corresponds to a distance between the wall of the terminal block and the housing, the gasket configured to reduce vibration between the housing and the terminal block.
 9. The battery pack of claim 6, wherein the gasket is a first gasket and wherein a second gasket is positioned between the printed circuit board and the terminal block, the second gasket preventing fluid and debris from entering the terminal block.
 10. The battery pack of claim 9, wherein the second gasket includes a set of openings, each of the set of openings of the second gasket corresponding an opening in a second wall of the terminal block.
 11. The battery pack of claim 6, wherein the gasket covers and extends beyond an outer periphery of the wall of the terminal block.
 12. The battery pack of claim 6, wherein each of the openings in the gasket entirely surrounds the respective opening in the terminal block.
 13. The battery pack of claim 6, wherein the gasket includes a first surface that abuts a first surface of the housing and a second surface that abuts a second surface of the housing.
 14. The battery pack of claim 6, further comprising a frame member positioned within the housing and configured to support the printed circuit board.
 15. The battery pack of claim 14, wherein the gasket includes a first surface that abuts a first surface of the housing and a second surface that is opposite the first surface, the second surface abutting the wall of the terminal block and a portion of the frame member.
 16. A battery pack for use with a power tool, the battery pack comprising: a housing having an internal cavity in which one or more battery cells are supported, the housing having a set of openings; a printed circuit board supported within the housing, the battery cells being in electrical communication with the printed circuit board; battery pack contacts coupled to and in electrical communication with the printed circuit board; a terminal block supported by the printed circuit board and enclosing the battery pack contacts, each of the battery pack contacts being accessible through one of the set of openings in the housing and the terminal block; a first gasket positioned between a first wall of the terminal block and the housing, the first gasket including a first surface, a second surface that is opposite the first surface, and a third surface, the first surface being in contact with a first surface of the housing, the second surface being in contact with the wall of the terminal block, the third surface being in contact with a second surface of the housing; and a second gasket positioned between a second wall of the terminal block and the printed circuit board.
 17. The battery pack of claim 16, wherein the gasket covers and extends beyond an outer periphery of the first wall of the terminal block.
 18. The battery pack of claim 16, wherein each of the openings in the gasket entirely surrounds the respective opening in the terminal block.
 19. The battery pack of claim 16, wherein the first gasket includes a first set of openings and the second gasket includes a second set of openings, each of the first set of openings corresponding to an on opening in the first wall of the terminal block and each of the second set of openings corresponding to an opening in the second wall of the terminal block.
 20. The battery pack of claim 16, wherein each of the first gasket and the second gasket prevent water and debris from entering the terminal block.
 21. A power tool comprising: a housing including a battery-receiving portion that removably receives a battery pack, and device contacts supported by the housing, the device contacts configured to mechanically and electrically interface with the battery pack; and a coating covers at least a portion of each of the device contacts, the coating being an insulator.
 22. The power tool of claim 21, wherein the coating is a spray acrylic. 